WORKSHOP MANUAL - HORNET2-S-OX

This winch is part of a group of winches whose designs have undergone extensive testing. The end user can

now enjoy a professional highly engineered high performance electric winch capable of operating in the most demanding of situations.The small compact size combined with its pulling power make it an ideal winch

for maximum impact when faced with minimal installation space

HORNET 2 - SWORKSHOP MANUAL WITH DRAWINGS

RED Winches

Drawing not to be reproduced or distributed in any format or method without specific permission from Redstart//Design.

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Telephone: +44 (0)1460 67744Email: [email protected]

WINCHTYPE

WINCHDESCRIPTION:

RED WinchesWORKSHOP MANUAL

ULTIMATE PERFORMANCE WINCH

HORNET 2 (S) TWIN MOTOR, HIGH SPEED 12V / 24V DC, AIR BRAKE

UNLESS SPECIFIED

M8M10M12M16M20 180 Nm

130 Nm65 Nm35 Nm20 Nm10 NmM6TORQUEFASTENER

114

.5

51.

0

49.

5

25.

0 149.0

376.5 27

M128.0 MIN

PLATE THICKNESS

142

.0

363

M12

254.0 314.0

30.0

65.

25

114

.5

226.0

296

.5

WARNING:MOUNTING PLATE THICKNESS IS IMPORTANTIN SAFE, RELIABLE OPERATION OF THE WINCHIF THE THICKNESS IS LESS THAN 8mm ITMAY DAMAGE THE WINCH AND INVALIDATE ANYWARANTY ON THE WINCH.

REV. DATE DESCRIPTION SIG

A 05/02/2017 WORKSHOP ISSUE NJ


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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesWINCH DIMENSIONS


TWIN MOTOR, HIGH SPEED 12V / 24V DC, AIR BRAKEHORNET 2

SMALL AMOUNT OF GREASETO BE APPLIED ON SPLINE FOR LUBRICATING ON ASSEMBLY SMALL AMOUNT OF GREASE

TO BE APPLIED ON DRIVEDOG WHEN ASSEMBLED

LOWER FASTENING BOLTS8off IN TOTAL.

UNLESS SPECIFIED

M8M10M12M16M20 200 Nm


MOTOR ASSEMBLY

ENSURE ALL FASTENERSARE TORQUED TO THE CORRECTVALUES

LOCTITE 234 (THREADLOCKER)TO BE APPLIED ON ALL FASTENERS

WINCH HOUSINGGEARBOX

WINCH HOUSINGFREESPOOL

FRONT FASTENING BOLTS8off IN TOTAL.

WINCH CAN BE MOUNTED EITHER ON THE FRONTOR THE LOWER FACE. IT IS NOT NECESSARY TO USEFRONT AND LOWER MOUNTED BOLTS.

BRAKE UNIT

M5 SKT CAP HEAD SCREWSREMOVE THESE TO ACCESS THE GEARBOX

HORNET2-MD-20 2X

HORNET2-MD-21 1X

HORNET2-MD-22 1X

HORNET2-MD-24 1X

MOTORGEAR

INTERMEDIATEGEAR

DRIVE GEAR

SHAFT GEAR

STANDARDGEARSET SHOWN

M5 SKT CAP HEAD SCREWSREMOVE THESE TO ACCESS THE FREESPOOL AND DRIVE SHAFT

Grease Specification:Castrol Spherol L-EP 2 or BP Energrease LS-EP 2

BRAKE UNITREMOVED FOR CLARITY


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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesREMOVING BRAKE & MOTORS


HORNET 2 TWIN MOTOR, HIGH SPEED 12V / 24V DC, AIR BRAKE

UNLESS SPECIFIED

M8M10M12M16M20 200 Nm




MAIN DRIVESHAFT

KEYWAYS TO BEA FIRM PRESSFIT. JACKING SCREWUSED TO REMOVETHEM

TO REMOVE CLUTCH PLATE:REMOVE CLUTCH PLATEPINS FIRST

PISTONWITH O-RINGSFITTED

ENGAGESPRING

AIR FEEDNOZZLE

CLUTCH PLATE

SPECIAL TOOL REQUIREDTO COVER UP SLOT EDGEINTERNALLY WHENINSERTING PISTONTO PROTECT O-RINGS

GREASESPLINE WITHCOPPER SLIPONLY

RETAINING PINS


GREASE

DUCK OIL ORLIGHT ENGINEERINGOIL ONLY

COPPER SLIPGREASE TO BE APPLIED ON SPLINE

TO REMOVE CLUTCH PLATE PINS:LOSEN BOLTS (x2) ON FRONT OFCLUTCH PLATE

ENGAGEMENT SLOTS x 4


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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesFREESPOOL DETAILS



UNLESS SPECIFIED

M8M10M12M16M20 200 Nm


AIR FEED FOR BRAKEFROM WINCH AIRBRAKE SOLENOID VALVE

O-RINGS MUST BE ALLLIGHTLY OILED BEFORE ASSEMBLY

HIGH TEMPERATURE O-RINGSMUST BE USED

ABU-MD-021X

N2281X

ABU-MD-011X

ABU-MD-02 1X

N2301X

ABU-MD-031X

ENTEX-916X

M4 x 164X

ABU-MD-053X

ABU-MD-07 2X

ABU-MD-06 1X

M4 x 16 4X

C1300-070 1X

MN036X2.5 1X

M5 x 163X

ABU-MD-081X

618051X

BRAKE PAD

1206621_AMTE-M-H-M51X

153097_QSLV-1_8-6-I1X



WARNING:

ONLY REMOVE BRAKE DISCSCREWS WHILE THE AIR IS ON.

AIR MUST BE APPLIED TO THE UNIT TOTAKE PRESSURE OFF THE BRAKE PADS BEFORE ATTEMPTING TO REMOVE SCREWS


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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesBRAKE ASSEMBLY



81

17

19

9

2

4

14

15

6

5

3

16

ALUMINIUM END CAP

CLAMP PINSSREW INTOGEARBOX HOSUINGOF WINCH

12

10

11

BRUSH PACK FITTED TO THEBACK SIDE OF THIS FRONT END CAP

WITH EACH MOTORYOU WILL RECIEVE:

2 x M6 PINS2 x 1/4" UNC PINS

18

13


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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesMOTOR ASSEMBLY



UNLESS SPECIFIED

M8M10M12M16M20 180 Nm


238

151

171.5

BRUSH PACKIN FRONT OF MOTOR

USE SMALL ZIP TIETO HOLD THE COVERS DOWNWHEN USED ON ROUGH TERRAINOR TRAVELLING AT HIGH SPEED

M8 EARTH CONNECTION x 3

POSITIVE CONNECTION

O-RING IN END PLATE

With the appropriate battery and alternator system, these OX Motors will providetremendous pulling power and a very high drum speed at no-load when respooling the ropeback on to the drum.

Never allow the OX MOTOR to ‘over speed’ or run in a no-load situation for too long as the armature could become damaged through revolving too fast.

RED WINCHESBUS BAR COVER

116.0

AIR BRAKE SOLENOID

EXHAUST AIRCOMES FROMTOP

RED WINCHESBUS BAR SET

ALBRIGHT SOLENOIDSHEAVY DUTY




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WINCHDESCRIPTION:




AIR FEED FORAIR BRAKESOLENOID

AIR BRAKESOLENOID

ALBRIGHT SOLENOID: DC88-1012PL (12V)ALBRIGHT SOLENOID: DC88-1017PL (24V)

EARTH / NEGATIVE WIRE FROM YOUR TRUCK GOES HERE.TO FEED MOTOR.

70mm2 MINIDEALLY 100mm2OR GREATERM8 CONNECTION

TWO CABLES CANBE CONNECTED

MUST GO BACK TO YOURBATTERIES DIRECTLYTO GIVE BESTPOSSIBLE PERFORMANCE

12v OR 24v POSITIVE WIRE FROM YOUR TRUCK GOES HERE.TO FEED MOTORS

70mm2 MINIMUMIDEALLY 100mm2OR GREATERM8 CONNECTION

TWO CABLES CANBE CONNECTED

125.0 127.9

12v & 24v SETUP WITH SOLENOIDS

IF YOU ARE RUNNING YOUR WINCH POWER TO THEMOTORS ON 24v THEN YOU DO NOT NEED 24v SOLENOIDS. THE 24v POWER WILL TRANSFER THROUGH THE SOLENOIDS TO THE WINCH MOTORS

IF YOU ARE RUNNING 24v ON YOUR VEHICLE SYSTEMS AND SIGNALS THEN YOU WILL NEED 24v SOLENOIDS AND A 24v AIR SOLENOID AS THESE ARE ONLY RATED AT 12v NORMALLY FOR SIGNAL VOLTAGE


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WINCHTYPE

WINCHDESCRIPTION:




HORNET2-MD-02 1x

HORNET2-MD-22 1x

HORNET2-MD-23 1x

HORNET2-MD-20 2x

HORNET2-MD-21 1x

HORNET2-MD-20 2x

M5 x 16 24x

4202-ATN94x

4202-ATN94x

61902 3x

619023x

619023x

HORNET2-MD-24 1x

16006 2x

HORNET2-MD-011x

HORNET2-MD-18S1x

M12 x 508x

HORNET2-MD-162x

HORNET2-MD-08S4x

HORNET2-MD-07S1x

HORNET2-MD-051x

VL170 SEAL2x61822-2RS2x

M12 x 308x

M12 FORM C8x

HORNET2-MD-14 2x

L06-01 1x

HORNET2-MD-04 1x

SC30X40X4 1x

16006 2x

HORNET2-MD-12 1xHORNET2-MD-11 1x

HORNET2-MD-101xHORNET2-MD-132x

N1091xN8091x

6005 2x

4202-ATN9 4xM5 x 10 4x

4202-ATN94x

HORNET2-MD-06 1x

AIR BRAKE UNIT

MOTOR ASSEMBLY


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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesWINCH ASSEMBLY



GREASE APPLIED TO THESE GEAR TEETH

ANY RESIDUE OR LIQUID FOUND IN THE LOWER PART OF THE CASE CAN BE REMOVED.

Lubrication Details

As a guide grease must be applied to the gears in the end housing when serviced

The lubrication frequency is based on irregular winch usage in hours per month:

1-15 Hrs - Add grease and cover gears every 12 Months15-40 Hrs - Clean and Replace Grease Every 6 Months

This above based on dry above water level conditions. If winch has been used within water or wet muddy ground for more than 50% of the hours specified the greasing / servicing frequency needs to be:

1-15 Hrs - Add grease and cover gears every 6 Months15-40 Hrs - Clean and Replace Grease Every 3 Months



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WINCHTYPE

WINCHDESCRIPTION:

RED WinchesGREASE / LUBRICATION


HORNET 2 TWIN MOTOR, HIGH SPEED 12V / 24V DC, AIR BRAKE

This winch is part of a range of winches produced by RED Winches Ltd that are designed for high speed and high power. This winch will pull rope onto its drum quickly and with power. If operated without care and attention this winch could easily damage fingers, hands and in some cases eyesight.The winch is powered by DC voltage, in most cases 12v, but also 24v systems can be used to power the winch. The current draw on this DC voltage can be high so care and attention must be taken when operating the winch that the electrical power to the motors is not exposed to the operator.The winch should only be operated by a person who has been authorised to do so or has been trained to operate it safely.

Safety - Hornet Winch

Safety Instructions - Hornet Winch

The Winch

Set-up Procedure

The winch is an excellent choice when it comes to speed and power for electric winching.It has been designed specifically for high performance and durability.The winch can give you speeds of 50m/min for the standard model, and 65m/min with the Hornet ‘Overdrive’ gear set (available separately) giving you a choice so you have the power and speed when you need it. The winch body is CNC machined from high grade heat treated aerospace aluminium from solid billets. Its patented brake system offers something previously unavailable on a winch and ensures the winch stops instantly when your finger it taken off the winch control button.

You can also have the Hornet come with the Overdrive Kit which makes it 1.5 times faster...his is free if you specify it at the time of ordering.

Springs apply pressure to a steel disc which then applies pressure to the brake disc and its material when the winch is not in use. This applies the brake and stops the winch drum from moving under load and from spooling out the rope.

An air solenoid for the air brake is fitted next to the motors at the top of the winch. This is fed by an air supply from the ARB compressor.When you winch in or out you energise your Albright motor solenoids this also energises the air solenoid valve for the brake on top of the winch. This then allows air to go into a specially designed chamber that releases the brake instantly. When you remove your winching finger from the controls the air solenoid dumps the air and the springs apply the brake disc onto the brake pads.

This means compared to normal winching you do not get overrun or excess rope causing snatching and jerking as the vehicle takes up the slack rope that has been spooled out. This design has been submitted for full patent and is currently protected and patent pending.

The electrical power of this winch is currently supplied by two OX Motors, 12v (7HP). These are supplied normally with a 12v supply from your vehicle onto the high efficiency copper busbar assemblies found on top of the motors. The high power Albright motor solenoids are used to switch direction of the motors and at the same time provide a feed to the 12v brake system via their signal terminals.

The winch air brake system:

The drum is mechanically driven by a solid steel hardened clutch plate. This is a very tough hardened plate.The clutch plate is driven from the gearbox by a solid steel central shaft passing through the middle of the drum. The drive system has been built for strength and durability.

All our winches are now supplied with Plasma Locks to hold the synthetic rope onto the drum, proven method and very reliable.It is a nice simple solution to ensure you always have the minimum amount of line wraps on your winch drum.With the Plasma Lock installed you can pull your rope line out with confidence that it won't leave you without any line on the drum!The Plasma lock has been designed for a variety of line gauges and you can feel confident that at least 8-10 wraps remain on your drum, reducing greatly the chances of a slippage.The Plasma Lock is made from double thickness, heavy duty bright red webbing and is 150mm x 40mm (approx).

Drum

The gearbox has been specifically designed for strength, power and ease of service. All gears are manufactured from 655-M13 nickel chromium molybdenum steel and case hardened to give maximum strength (1100 N/mm²) and excellent durability. The end covers are sealed via an o-ring and groove, ensuring a watertight seal. Once the cover is removed access to all gears is possible and only takes a short time to service and re-assemble. The gearbox runs in grease not oil making it much easier to service in the field.

Gearbox

WARNING! THIS WINCH IS ONLY SUITABLE FOR WINCHING SITUATIONS / APPLICATIONSWARNING! Ensure all fasteners and connections are adequately connected or secured before using the winchMaintain the equipment in good condition (use an authorised servicing agent if required)Replace or repair damaged parts. Use genuine parts only. Unauthorised parts may be dangerous and will invalidate any warranty.Use a qualified person to lubricate if required and maintain the equipment. Before use, ensure all parts are clean and free of contamination / dirt.DO NOT use solvent cleaners to clean this winchUse the equipment in a suitable work or operational area, keep winching area clean and tidy and free from unrelated materials, and ensure that there is adequate lighting while setting and operating the winch.Keep the winch and winch rope clean for best and safest performance.The maximum line load is 4500kg. DO NOT exceed this rated capacity.When operating remove ill-fitting clothing. Remove ties, watches, rings and other loose jewellery, and contain long hair.Maintain correct balance and footing, do not over reach. Ensure the floor / ground is not slippery and wear appropriate footwear.Before using the winch check that there are no overhead or surrounding obstructions.The speed during operation must be kept steady and constant. Do not generate sudden movements or shock loads.

DO NOT use the winch for a task it is not designed to perform.DO NOT use the equipment if damaged.DO NOT exceed the rated capacity of the equipment.DO NOT use the equipment when you are tired or under the influence of alcohol, drugs or intoxicating medication.DO NOT allow untrained persons to use the equipment unsupervisedDO NOT attempt to transport a load outside JLR designated safe load / unload areas.DO NOT make any modifications to the equipment

DO NOT operate the winch and handle the synthetic rope without approved winching gloves and appropriate PSE

(1) Check winch as per the safety instructions(2) Check winch is situated correctly for the task at hand(3) Check rope is on drum securely and is not tangled(4) Check power connection to winch(5) Ensure Compressor is on and the winch has air pressure to it(6) Winch is now ready to operate

The winch can release and winch line in at 40m/m or faster, this is much faster than a normal winchThe winch gearbox has gears that are straight cut for strength and durabilityThe winch gearbox is noisier than other winches due to the rotational speeds of the gears, especially when not under load.The compressor will run and vibrate whenever it needs to topup the air in the system, the winch uses very little air to operate.This compressor could start when the winch is not being operated if the air pressure in the system drops

Startup

Q & A

Q: How do I store the rope on the drum?A: Always leave the drum and rope neatly spooled after use with the rope clean and evenly layered

Q: What should I do if the winch has been used in muddy / wet / dirty conditionsA: After a prolonged dirty wet operation clean and wash the rope and clean all connections

Q: What if the winch stops while operating?A: If the winch overloads, i.e. it stops under load, release the control button immediately and assess the situation otherwise you could damage the motors. Check all electrical connections to ensure they are secure and look normal.

DESCRIPTION COMPLETED YES / NO NOTES

ALL BOLTS AND SCREWS FITTED CORRECTLY

ALL BOLTS AND SCREWS (APART FROM THOSE INDICATED) SECURED WITH LOCTITE 234

ALL BOLTS AND SCREWS FITTED CORRECTLY AND TIGHTENED TO THE CORRECT TORQUE SETTING

GEARS FULLY GREASED AND MINIMUM OF 1" OF GREASE IN LOWER PART OF CASE

AIR BRAKE ASSEMBLY LIGHTLY GREASED AND ALL O-RINGS FITTED.

AIR BRAKE ASSEMBLY FULLY TESTED TO ENSURE BRAKE PADS ARE FREE TO ROTATE WITH NO HIGH SPOTS WHEN AIR IS APPLIED AND THE BRAKES

ARE OFF.AIR SOLENOID CHECKED FOR LEAKS.

ENSURE THREADLOCKKING IS NOT LEAKING AIR

AIR FREESPOOL GREASED ON SPLINE AND DISC. DUCK OIL APPLIED INTERNALLY ON O-RINGS AND PISTON.

AIR FREESPOOL FUNCTION TESTED AT LEAST 20 TIMES. TO WORK EVERY TIME OTHERWISE STRIP DOWN AND CHECK.

WIRING TESTED PRIOR TO ASSEMBLING ON WINCH.

WINCH POWERED AND TESTED IN BOTH DIRECTIONS. AIR FREESPOOL AND BRAKE SOLENOID CHECKED TO ENSURE CORRECT OPERATION.

BUS BAR ARRANGEMENT CHECKED FOR CONTINUITY.ZIP TIES FITTED ON COVERS

NAME OF ENGINEERBUILT / PERFORMED

FINAL CHECKSSIGNATURE WINCH SERIAL NUMBER


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Telephone: +44 (0)1460 67744Email: [email protected] DESCRIPTION:

RED WinchesHORNET2-S


INSPECTION SHEET HORNET 2 WINCH, FINAL BUILDCHECK SHEET

Documents

WORKSHOP MANUAL - HORNET2-S-OX